Robotic surgical devices, systems, and related methods

ABSTRACT

The embodiments disclosed herein relate to various medical device components, including components that can be incorporated into robotic and/or in vivo medical devices. Certain embodiments include various modular medical devices for in vivo medical procedures.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority as a continuation of U.S. applicationSer. No. 14/212,686, filed Mar. 14, 2014, and entitled “Robotic SurgicalDevices, Systems, and Related Methods,” which claims the benefit under35 U.S.C. § 119(e) to U.S. Provisional Application 61/792,508, filedMar. 15, 2013, and entitled “Robotic Surgical Devices, Systems andMethods,” all of which are hereby incorporated herein by reference intheir entireties.

TECHNICAL FIELD

The embodiments disclosed herein relate to various medical devices andrelated components, including robotic and/or in vivo medical devices andrelated components. Certain embodiments include various robotic medicaldevices, including robotic devices that are disposed within a bodycavity and positioned using a support component disposed through anorifice or opening in the body cavity. Further embodiment relate tomethods of operating the above devices.

BACKGROUND

Invasive surgical procedures are essential for addressing variousmedical conditions. When possible, minimally invasive procedures such aslaparoscopy are preferred.

However, known minimally invasive technologies such as laparoscopy arelimited in scope and complexity due in part to 1) mobility restrictionsresulting from using rigid tools inserted through access ports, and 2)limited visual feedback. Known robotic systems such as the da Vinci®Surgical System (available from Intuitive Surgical, Inc., located inSunnyvale, Calif.) are also restricted by the access ports, as well ashaving the additional disadvantages of being very large, very expensive,unavailable in most hospitals, and having limited sensory and mobilitycapabilities.

There is a need in the art for improved surgical methods, systems, anddevices.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a side view of a robotic surgical device according to oneembodiment.

FIG. 1B is perspective front view of the device of FIG. 1 .

FIG. 1C is a perspective view of the device of FIG. 1 .

FIG. 1D is an end view of the device of FIG. 1 .

FIG. 2A is a cutaway view of the interior body and shoulder of therobotic medical device, according to one embodiment.

FIG. 2B is a rotated cutaway view of the robotic medical device of FIG.2A.

FIG. 2C is a perspective cutaway view of the medical device, accordingto the embodiment of FIG. 2A.

FIG. 2D is a further cutaway perspective view of the medical devicebody, according to the embodiment of FIG. 2A.

FIG. 2E is a cutaway view of the lower body and shoulder of a roboticdevice, according to the embodiment of FIG. 2A.

FIG. 3A is a cutaway side view of the upper arm of the robotic medicaldevice, according to one embodiment.

FIG. 3B is a perspective view of the embodiment of FIG. 3A.

FIG. 3C is a different perspective view of the embodiment of FIG. 3A.

FIG. 3D is a reverse perspective view of the embodiment of FIG. 3A.

FIG. 3E is an alternate perspective view of medical device as depictedin FIG. 3D.

FIG. 4A is a cutaway view of the internal components of the right upperarm of a robotic device, according to one embodiment.

FIG. 4B is a rotated sideview of the embodiment of FIG. 4A.

FIG. 4C is a further rotated sideview of the embodiment of FIG. 4A.

FIG. 4D is an endlong view of the embodiment of FIG. 4A.

FIG. 4E is a further endlong view of the embodiment of FIG. 4A.

FIG. 5A is a endlong view of the lower arm of a robotic device,according to one embodiment.

FIG. 5B is cutaway sideview of the internal components of the lower armof the embodiment of FIG. 5A along line A-A.

FIG. 5C is cutaway sideview of the internal components of the lower armof the embodiment of FIG. 5A along line B-B.

FIG. 6A is a cross-sectional view of the end effector portion of theforearm depicting the electrical portions, according to an exemplaryembodiment.

FIG. 6B is a top perspective view of external view of complimentaryportion of the forearm to the embodiment of FIG. 6A.

FIG. 7 is a bottom perspective schematic of the internal components ofthe lower arm of a robotic device, according to one embodiment.

FIG. 8A is cutaway sideview of the internal components of the lower armof the embodiment of FIG. 5A along line A-A, detailing furtherelectronic components.

FIG. 8B is a close view of the section C-C of the embodiment of FIG. 8A.

FIG. 9A is a perspective view of the exterior of the forearm accordingto one embodiment.

FIG. 9B is an internal view perspective of the embodiment of FIG. 9A

FIG. 10A is a perspective view of one embodiment of the robotic devicecomprising an inner fluidic seal.

FIG. 10B is a perspective view of the embodiment of FIG. 10A furthercomprising further outer fluidic seal.

FIG. 11A is a side cutaway view of one embodiment of a rigid-flex PCBcomponent within the forearm of the device.

FIG. 11B is a further perspective view of the embodiment of FIG. 11A.

FIG. 12A depicts a top view of a robotic device during insertion,according to one embodiment.

FIG. 12B is a front view of the device of FIG. 12A.

FIG. 12C is a side view of the device of FIG. 12A.

FIG. 12D is a perspective view of the device of FIG. 12A.

FIG. 13A depicts a top view of a robotic device during insertion,according to one embodiment.

FIG. 13B is a front view of the device of FIG. 13A.

FIG. 13C is a side view of the device of FIG. 13A.

FIG. 13D is a perspective view of the device of FIG. 13A.

FIG. 14A depicts a top view of a robotic device during insertion,according to one embodiment.

FIG. 14B is a front view of the device of FIG. 14A.

FIG. 14C is a side view of the device of FIG. 14A.

FIG. 14D is a perspective view of the device of FIG. 14A.

FIG. 15A depicts a top view of a robotic device during insertion,according to one embodiment.

FIG. 15B is a front view of the device of FIG. 15A.

FIG. 15C is a side view of the device of FIG. 15A.

FIG. 15D is a perspective view of the device of FIG. 15A.

FIG. 16A depicts a top view of a robotic device during insertion,according to one embodiment.

FIG. 16B is a front view of the device of FIG. 16A.

FIG. 16C is a side view of the device of FIG. 16A.

FIG. 16D is a perspective view of the device of FIG. 16A.

FIG. 17A depicts a top view of a robotic device during insertion,according to one embodiment.

FIG. 17B is a front view of the device of FIG. 17A.

FIG. 17C is a side view of the device of FIG. 17A.

FIG. 17D is a perspective view of the device of FIG. 17A.

DETAILED DESCRIPTION

The various systems and devices disclosed herein relate to devices foruse in medical procedures and systems. More specifically, variousembodiments relate to various medical devices, including robotic devicesand related methods and systems. Certain implementations relate to suchdevices for use in laparo-endoscopic single-site (LESS) surgicalprocedures.

It is understood that the various embodiments of robotic devices andrelated methods and systems disclosed herein can be incorporated into orused with any other known medical devices, systems, and methods. It isunderstood that the various embodiments of robotic devices and relatedmethods and systems disclosed herein can be incorporated into or usedwith any other known medical devices, systems, and methods. For example,the various embodiments disclosed herein may be incorporated into orused with any of the medical devices and systems disclosed in copendingU.S. application Ser. No. 11/766,683 (filed on Jun. 21, 2007 andentitled “Magnetically Coupleable Robotic Devices and Related Methods”),Ser. No. 11/766,720 (filed on Jun. 21, 2007 and entitled “MagneticallyCoupleable Surgical Robotic Devices and Related Methods”), Ser. No.11/966,741 (filed on Dec. 28, 2007 and entitled “Methods, Systems, andDevices for Surgical Visualization and Device Manipulation”), 61/030,588(filed on Feb. 22, 2008), Ser. No. 12/192,663 (filed Aug. 15, 2008 andentitled “Medical Inflation, Attachment, and Delivery Devices andRelated Methods”), Ser. No. 12/192,779 (filed on Aug. 15, 2008 andentitled “Modular and Cooperative Medical Devices and Related Systemsand Methods”), 61/640,879 (filed on May 1, 2012), Ser. No. 13/493,725(filed Jun. 11, 2012 and entitled “Methods, Systems, and DevicesRelating to Surgical End Effectors”), Ser. No. 13/546,831 (filed Jul.11, 2012 and entitled “Robotic Surgical Devices, Systems, and RelatedMethods”), 61/680,809 (filed Aug. 8, 2012), Ser. No. 13/573,849 (filedOct. 9, 2012 and entitled “Robotic Surgical Devices, Systems, andRelated Methods”), and Ser. No. 13/738,706 (filed Jan. 10, 2013 andentitled “Methods, Systems, and Devices for Surgical Access andInsertion”), and U.S. Pat. No. 7,492,116 (filed on Apr. 3, 2007 andentitled “Robot for Surgical Applications”), U.S. Pat. No. 7,772,796(filed on Nov. 29, 2007 and entitled “Robot for Surgical Applications”),U.S. Pat. No. 8,179,073 (issued May 15, 2012, and entitled “RoboticDevices with Agent Delivery Components and Related Methods”), U.S. Pat.No. 8,343,171 (filed on Jul. 11, 2008 and entitled “Methods and Systemsof Actuation in Robotic Devices”), and U.S. Pat. No. 8,679,096 (filedNov. 26, 2008 and entitled “Multifunctional Operational Component forRobotic Devices”), all of which are hereby incorporated herein byreference in their entireties.

Certain device and system implementations disclosed in the applicationslisted above can be positioned within a body cavity of a patient incombination with a support component similar to those disclosed herein.An “in vivo device” as used herein means any device that can bepositioned, operated, or controlled at least in part by a user whilebeing positioned within a body cavity of a patient, including any devicethat is coupled to a support component such as a rod or other suchcomponent that is disposed through an opening or orifice of the bodycavity, also including any device positioned substantially against oradjacent to a wall of a body cavity of a patient, further including anysuch device that is internally actuated (having no external source ofmotive force), and additionally including any device that may be usedlaparoscopically or endoscopically during a surgical procedure. As usedherein, the terms “robot,” and “robotic device” shall refer to anydevice that can perform a task either automatically or in response to acommand from an external console or control system, as has beendescribed previously.

Certain embodiments provide for insertion of the present invention intothe cavity while maintaining sufficient insufflation of the cavity.Further embodiments minimize the physical contact of the surgeon orsurgical users with the present invention during the insertion process.Other implementations enhance the safety of the insertion process forthe patient and the present invention. For example, some embodimentsprovide visualization of the present invention as it is being insertedinto the patient's cavity to ensure that no damaging contact occursbetween the system/device and the patient. In addition, certainembodiments allow for minimization of the incision size/length. Furtherimplementations reduce the complexity of the access/insertion procedureand/or the steps required for the procedure. Other embodiments relate todevices that have minimal profiles, minimal size, or are generallyminimal in function and appearance to enhance ease of handling and use.

Certain implementations disclosed herein relate to “combination” or“modular” medical devices that can be assembled in a variety ofconfigurations. For purposes of this application, both “combinationdevice” and “modular device” shall mean any medical device havingmodular or interchangeable components that can be arranged in a varietyof different configurations. The modular components and combinationdevices disclosed herein also include segmented triangular orquadrangular-shaped combination devices. These devices, which are madeup of modular components (also referred to herein as “segments”) thatare connected to create the triangular or quadrangular configuration,can provide leverage and/or stability during use while also providingfor substantial payload space within the device that can be used forlarger components or more operational components. As with the variouscombination devices disclosed and discussed above, according to oneembodiment these triangular or quadrangular devices can be positionedinside the body cavity of a patient in the same fashion as those devicesdiscussed and disclosed above.

As shown generally in FIGS. 1A, 1B, 1C, and 1D, certain exemplaryembodiments relate to a device 10 having a body 12 with two arms 14A,14B operably coupled thereto. The body 12 as shown further comprises acasing 30. The body 12 is also referred to as a “device body.” Each arm14A, 14B has a first coupling link 16A, 16B that couples the arm 14A,14B to the body 12.

As is best shown in FIGS. 1B-1C, this first coupling link 16A, 16B canalso be referred to herein as a “first coupling component” or “shoulderlink” and is part of the first rotatable joint 24A, 24B (also referredto herein as the “shoulder joint”). Each arm 14A, 14B has an upper arm(also referred to herein as an “inner arm,” “inner arm assembly,” “innerlink,” “inner link assembly,” “upper arm assembly,” “first link,” or“first link assembly”) 18A, 18B, and a forearm (also referred to hereinas an “outer arm,” “outer arm assembly,” “outer link,” “outer linkassembly,” “forearm assembly,” “second link,” or “second link assembly”)20A, 20B.

As is shown in FIGS. 1A-1C and further discussed in relation to FIGS.12-17 below, the upper arms 18A, 18B are rotatably coupled to thecoupling links 16A, 16B, which are rotatably coupled to the body 12.Each arm 14A, 14B has a second coupling link 22A, 22B that couples theupper arm 18A, 18B to the forearm 20A, 20B. This second coupling link22A, 22B can also be referred to herein as a “second coupling component”or “elbow link” and is part of the second rotatable joint 26A, 26B (alsoreferred to herein as the “elbow joint”). More specifically, in theright arm 14A, the upper arm 18A is rotatably coupled to the forearm 20Aat the elbow joint 26A via the elbow link 22A, while in the left arm14B, the upper arm 18B is rotatably coupled to the forearm 20B at theelbow joint 26B via elbow link 22B.

As shown, each of the arms 14A, 14B also has an end effector 28A, 28Boperably coupled to the distal end of the forearm 20A, 20B. An endeffector can also be referred to herein as an “operational component.”

In one implementation, each of the arms 14A, 14B has six degrees offreedom. That is, as explained in further detail below, each arm 14A,14B has three degrees of freedom at the shoulder, one degree of freedomat the elbow, and two degrees of freedom at the end effector (which canbe rotated—end effector roll—and opened/closed). As such, the sixdegrees of freedom of each arm 14A, 14B are analogous to the degrees offreedom of a human arm, which also has three degrees of freedom at theshoulder and one at the elbow. One advantage of an arm having fourdegrees of freedom (with an end effector having two degrees of freedom)is that the end effector can have multiple orientations at the sameCartesian point. This added dexterity allows the surgeon or other usermore freedom and a more intuitive sense of control while operating thedevice.

The internal components of the body 12 are depicted in the variousembodiments shown in FIGS. 2A, 2B, 2C, 2D, and 2E. The body 12 is shownin these figures without its casing 30. More specifically, these figuresdepict the right half of the body 12 and the internal components thatcontrol/actuate the right arm 14A. It is to be understood that theinternal components in the left half (not shown) thatoperate/control/actuate the left arm 14B are substantially the same asthose depicted and described herein and that the descriptions providedbelow apply equally to those components as well.

FIGS. 2A, 2B, and 2C include the internal structural or supportcomponents of the body 12. In one implementation, the body 12 has aninternal top cap 40, an internal support rod 42, and an internal supportchassis 44, as shown. The support rod 42 couples the top cap 40 to thesupport chassis 44. In certain embodiments, the support chassiscomprises an aluminum structure. In alternate embodiments, aninjection-molded polymer may be used. These components maintain thestructure of the body 12 and provide structural support for thecomponents disposed therein, and in certain embodiments are surroundedby a housing or shell. According to one embodiment, the internal top cap40 defines three partial lumens 46A, 46B, 46C as best shown in FIG. 2C.The top cap 40 couples to the body casing 30 such that each of thepartial lumens 46A, 46B, 46C is formed into a full lumen defined by thecoupling of the cap 40 and casing 30. As will be described in furtherdetail below, these lumens 46A, 46B, 46C can be configured to receivevarious wires, cords, or other components to be inserted into or throughthe body 12.

In contrast to FIGS. 2A-2C, FIG. 2D depicts the internal actuation andcontrol components of the right half of the body 12 with the internalstructural or support components hidden in order to better display theinternal actuation and control components. These internal actuation andcontrol components are configured to provide two degrees of freedom atthe shoulder joint 24A.

FIG. 2E is an enlarged view of the distal end of the body 12. In oneembodiment, certain of the internal components depicted in FIGS. 2D and2E are configured to actuate rotation at the shoulder joint 24A aroundaxis A (as best shown in FIG. 2B), which is parallel to the longitudinalaxis of the body 12. This rotation around axis A is also referred to as“yaw” or “shoulder yaw.” The rotation, in one aspect, is created asfollows. An actuator 60 is provided that is, in this implementation, amotor assembly 60. The motor assembly 60 is operably coupled to theproximal motor gear 62, which is coupled to the proximal driven gear 64such that rotation of the proximal motor gear 62 causes rotation of theproximal driven gear 64. The proximal driven gear 64 is fixedly coupledto a proximal transmission shaft 66, which has a distal transmissiongear 68 at the opposite end of the shaft 66. The distal transmissiongear 68 is coupled to a distal driven gear 70, which is fixedly coupledto the distal transmission shaft 72. A magnet holder 76 containing amagnet is also operably coupled to the distal transmission gear 68. Theholder 76 and magnet are operably coupled to a magnetic encoder (notshown).

It is understood that the magnet holder 76, magnet, and magnetic encoder(and those similar components as discussed elsewhere herein in relationto other joints) are components of an absolute position sensor that isthe same as or substantially similar to one or more of the absoluteposition sensors disclosed in U.S. application Ser. Nos. 13/573,849filed Oct. 9, 2012, and 13/833,605 filed Mar. 15, 2013, which are herebyincorporated by reference in their entirety. The distal transmissionshaft 72 is fixedly coupled at its distal end to a rotatable pitchhousing 74 (as best shown in FIGS. 2B and 2E) such that rotation of thedistal driven gear 70 causes rotation of the shaft 72 and thus rotationof the housing 74 around axis A as shown in FIG. 2B.

According to one implementation, certain other internal componentsdepicted in FIG. 2D are configured to actuate rotation at the shoulderjoint 24A around axis B (as best shown in FIG. 2D), which isperpendicular to the longitudinal axis of the body 12. This rotationaround axis B is also referred to as “pitch” or “shoulder pitch.” Therotation, in one embodiment, is created as follows. An actuator 80 isprovided that is, in this implementation, a proximal shoulder motorassembly 80. The motor assembly 80 is operably coupled to a proximalshoulder motor gear 82, which is coupled to the proximal shoulder drivengear 84 such that rotation of the proximal shoulder motor gear 82 causesrotation of the proximal shoulder driven gear 84. This driven gear 84 isfixedly coupled to a proximal shoulder transmission shaft 86, which hasa proximal shoulder transmission gear 88 at the opposite end of theshaft 86.

The proximal transmission gear 88 is coupled to a distal shoulder drivengear 90, which is fixedly coupled to the distal shoulder shaft 92. Amagnet holder 98 containing a magnet is also operably coupled to thedriven gear 90. The holder 98 and magnet are operably coupled to amagnetic encoder (not shown). As best shown in FIG. 2E, a portion of thedistal shoulder shaft 92 is disposed within the lumen 72A of the shaft72 described above and extends out of the distal end of the shaft 72into the housing 74. As best shown in FIG. 2E, the distal end of theshaft 92 is coupled to a rotation gear 94 that is a bevel gear 94. Therotation gear 94 is operably coupled to link gear 96, which is also abevel gear 96 according to one implementation. The link gear 96 isoperably coupled to the shoulder link 16A (discussed above) such thatrotation of the shaft 92 causes rotation of the rotation gear 94 andthereby the rotation of the link gear 96 and thus rotation of the link16A around axis B as best shown in FIG. 2D.

In this embodiment, the two axes of rotation are coupled. That is, ifsolely rotation around axis A (pure yaw) is desired, then the “pitchdrive train” (the motor 80 and all coupled gears and components requiredto achieve rotation around axis B) must match the speed of the “yawdrive train” (the motor 60 and all coupled gears and components requiredto achieve rotation around axis A) such that there is no relativeangular displacement between the pitch housing 74 and the rotation gear94. In contrast, if solely rotation around axis B (pure pitch) isdesired, then the yaw drive train must hold position while the pitchdrive train is actuated.

In one implementation as shown in FIG. 2A, the body 12 has a rigid-flexPCB 100 positioned in the body. The PCB 100 is operably coupled to andcommunicates with the motors 60, 80 and magnetic encoders (not shown) toperform the yaw and pitch functions.

According to another embodiment, at least one connection component isassociated with the body 12. More specifically, in this implementation,a power/communication line 102 and a cautery power line 104 are coupledat their proximal ends to one or more external power sources (not shown)and extend into the device 10 through one or more of the three lumens46A, 46B, 46C defined partially by internal top cap 40. The lines 102,104 extend through the body 12 and exit as shown in FIG. 2B and extendto the upper arm segment. In certain embodiments, the lines 102, 104 arenot continuous, but occur in series. In certain of these embodiments,the lines contain terminus at various PCB boards. In yet furtherembodiments of the lines may run in parallel.

In one embodiment, the body 12 can be coupled at its proximal end to apositioning rod (also referred to as an “insertion rod”) (not shown). Itis understood that the positioning rod can be any such known componentfor helping to position the device 10 and/or maintain and stabilize theposition of the device 10. According to one implementation, thepower/communication line 102 and/or the cautery power line 104 canextend proximally through one or more lumens in the positioning rod.

In one embodiment, any of the motors discussed and depicted herein canbe brush or brushless motors, such as brushless DC motors. Further, themotors can be, for example, 6 mm, 8 mm, or 10 mm diameter motors.Alternatively, any known size that can be integrated into a medicaldevice can be used. In a further alternative, the actuators can be anyknown actuators used in medical devices to actuate movement or action ofa component. Examples of motors that could be used for the motorsdescribed herein include the EC 10 BLDC+GP10A Planetary Gearhead, EC 8BLDC+GP8A Planetary Gearhead, or EC 6 BLDC+GP6A Planetary Gearhead, allof which are commercially available from Maxon Motors, located in FallRiver, Mass.

FIGS. 3A, 3B, 3C, 3D, 3E, 4A, 4B, 4C, 4D, and 4E according to oneembodiment, depict the internal components of the right upper arm 18A,which is shown in these figures without its casing. More specifically,these figures depict the right arm 14A and the internal componentstherein. It is understood that the internal components in the left upperarm 18B are substantially the same as those depicted and describedherein and that the descriptions provided below apply equally to thosecomponents as well.

FIGS. 3A-3E depict the internal components of the right upper arm 18A,including actuators, drive components, and electronics, with theinternal structural or support components hidden in order to betterdisplay the internal components. In contrast to FIGS. 3A-3E, FIGS. 4A-4Einclude both the internal actuator, drive, and electronics components,but also the internal structural or support components of the rightupper arm 18A.

In one embodiment, certain of the internal components depicted in FIGS.3A-3E are configured to actuate rotation at the shoulder link 16A aroundaxis C (as best shown in FIG. 3B), which is parallel to the longitudinalaxis of the right upper arm 18A. This rotation around axis C is alsoreferred to as “shoulder roll.” The rotation, in one aspect, is createdas follows: a first shoulder actuator 120 is provided that is, in thisimplementation, a motor assembly 120. This motor assembly 120 isoperably coupled to a first shoulder motor gear 122. This motor gear 122is supported by a first shoulder bearing pair 124. This motor gear 122is coupled to the shoulder driven gear 126 such that rotation of thefirst shoulder motor gear 122 causes rotation of the driven gear 126.The driven gear 126 is fixedly coupled to the shoulder link 16A suchthat rotation of the driven gear 126 causes rotation of the shoulderlink 16A around axis C as shown in FIG. 3B. The driven gear 126 issupported by a second bearing pair 128. A magnet holder 130 furthercomprising a magnet is also operably coupled to the driven gear 126. Theholder 130 and magnet are operably coupled to a magnetic encoder 132.

The rotation of the shoulder link 16A around axis C causes the rightupper arm 18A (and thus the forearm 20A) to rotate in relation to thebody 12. According to one embodiment, this rotation adds an additionaldegree of freedom not provided in prior two-armed surgical devices.

According to one implementation, certain of the internal componentsdepicted in FIGS. 3A-3E are configured to actuate rotation at the elbowlink 22A around axis D (as best shown in FIG. 3C), which isperpendicular to the longitudinal axis of the right upper arm 18A. Thisrotation around axis D is also referred to as “elbow yaw.” The rotation,in one aspect, is created as follows. An actuator 140 is provided thatis, in this implementation, a second upper arm motor assembly 140. Thismotor assembly 140 is operably coupled to the second upper arm motorgear 142, which is a beveled gear in this embodiment. This motor gear142 is supported by a bearing 144. The motor gear 142 is coupled to thedriven gear 146 such that rotation of the motor gear 142 causes rotationof the driven gear 146. The driven gear 146 is fixedly coupled to a linkgear 148, which is coupled to the gear teeth 158 (as best shown in FIG.3B) of the elbow link 22A such that rotation of the driven gear 146causes rotation of the elbow link 22A around axis D as shown in FIG. 3C.The driven gear 146 and link gear 148 are supported by a bearing pair150. Further, the elbow link 22A is supported by a bearing pair 152. Amagnet holder 154 containing a magnet is also operably coupled to theelbow link 22A. The holder 154 and magnet are operably coupled to amagnetic encoder 156.

According to one embodiment, the additional coupling of the link (ormesh) gear 148 and the elbow link 22A can provide certain advantages,including an additional external reduction (because the gear 148 hasfewer gear teeth than the elbow link 22A), shortening of the upper arm18A and improved joint range of motion. In various embodiments, as withthe embodiment shown in FIGS. 4A-E, the robotic devices represent animprovement in range of motion of the elbow joint by reducing therelative distance between the center of the rotational center of theelbow link 22A and the desired direction of travel and preventingphysical impediment (as is depicted by arrow A in FIG. 2B).

As shown in FIG. 4B, the upper arm 18A can have a rigid-flex PCB 160positioned therein. In one embodiment, the PCB 160 is operably coupledto and communicate with the actuators 120, 140 and magnetic encoders132, 156.

According to another embodiment, at least one connection component isassociated with the upper arm 18A. More specifically, in thisimplementation, the power/communication line 102 and the cautery powerline 104 enter through a port (not shown) at the proximal end of theupper arm 18A and exit through a port (not shown) at the distal end.

FIGS. 5A-9B depict various embodiments of a right forearm 20A. Thevarious implementations disclosed and depicted herein include theactuators, drive components, and electronics that can be used toaccomplish both tool roll and tool drive (open/close action), as will bedescribed in further detail below. As set forth below, the forearm 20Aalso has two electrically isolated cautery circuits, enabling bothbipolar and monopolar cautery end effectors. Certain embodiments areconfigured to allow for easy removal and replacement of an end effector(a “quick change” configuration). Further embodiments contain sealingelements that help to prevent fluid ingress into the mechanism.

According to one implementation, certain of the internal componentsdepicted in FIGS. 5A-5C are configured to actuate rotation at the endeffector 28A around axis E (as best shown in FIG. 5B), which is parallelto the longitudinal axis of the right forearm 20A. This rotation aroundaxis E is also referred to as “tool roll.” The rotation, in one aspect,is created as follows. An actuator 180 is provided that is, in thisimplementation, a motor assembly 180. The motor assembly 180 is operablycoupled to the motor gear 182, which is a spur gear in this embodiment.The motor gear 182 is coupled to the driven gear 184 such that rotationof the motor gear 182 causes rotation of the driven gear 184. The drivengear 184 is fixedly coupled to the roll hub 186, which is supported by abearing 188. The roll hub 186 is fixedly coupled to the tool baseinterface 190, which has external threads 190A which are threadablycoupled to the end effector 28A. Thus, rotation of the driven gear 184causes rotation of the roll hub 186, which causes rotation of the toolbase interface 190, which causes rotation of the end effector 28A aroundaxis E as shown in FIG. 5B.

In one embodiment, certain of the internal components depicted in FIGS.5A-5C are configured to actuate the end effector to open and close. Thisrotation of the end effector arms such that the end effector opens andcloses is also called “tool drive.” The actuation, in one aspect, iscreated as follows. An actuator 200 is provided that is, in thisimplementation, a motor assembly 200. The motor assembly 200 is operablycoupled to the motor gear 202, which is a spur gear in this embodiment.The motor gear 202 is coupled to the driven gear 204 such that rotationof the motor gear 202 causes rotation of the driven gear 204. The drivengear 204 is fixedly coupled to a tool drive nut 206, which is supportedby a bearing pair 208. The tool drive nut 206 has a threaded inner lumen206A, and this threaded inner lumen 206A is threadably coupled to thelead screw 210. More specifically, the outer threads of the lead screw210 are threadably coupled to the threads on the inner lumen 206A. Thelead screw 210 is rotationally coupled to the tool base interface 190(discussed above). More specifically, the tool base interface 190 has asquare-shaped inner lumen 190A, and the distal end of the lead screw 210has a square-shaped protrusion that fits within the inner lumen 190A,thereby coupling with the tool base interface 190. The distal end of thelead screw 210 can move translationally within the lumen 190A, butcannot rotate in relation to the tool base interface 190, so the leadscrew 210 can move translationally in relation to the tool baseinterface 190, but cannot rotate in relation thereto.

The lead screw 210 also has an insulating sleeve 212 disposed to anexternal portion of the lead screw 210 and thereby plays a role inmaintaining separate electrical cautery channels as will be describedbelow. Further, the lead screw 210 has a threaded inner lumen 210A,which is threadably coupled to the tool pin 214. The tool pin 214 isoperationally coupled to a known linkage mechanism within the endeffector 28A such that translation of the tool pin 214 causes thegrasper arms or blades to open and close. As such, actuation of gear 202causes rotation of the driven gear 204, which rotates the tool drive nut206. The rotation of the tool drive nut 206 causes the lead screw 210 totranslate as a result of the threadable coupling of the nut 206 and thescrew 210. The translation of the screw 210 causes the tool pin 214 totranslate, thereby causing the end effector 28A arms or blades to openand close.

In this embodiment, these two axes of rotation are coupled. That is, ifpure roll is desired, then the tool open/close drive train must matchthe speed of the roll train such that there is no relative angulardisplacement between the tool drive nut 206 and the tool base interface190.

According to one implementation, the end effector 28A can be quickly andeasily coupled to and uncoupled from the forearm 20A in the followingfashion. With both the roll and drive axes fixed or held in position,the end effector 28A can be rotated, thereby coupling or uncoupling thethreads 190A and 210A. That is, if the end effector 28A is rotated inone direction, the end effector 28A is coupled to the forearm 20A, andif it is rotated in the other direction, the end effector 28A isuncoupled from the forearm 20A.

In accordance with one embodiment, the forearm 20A has two independentcautery channels (referred to herein as “channel A” and “channel B”),which enables the use of either bipolar or monopolar cautery endeffectors with this forearm 20A.

Turning to FIG. 6A, the channel A components of certain exemplaryembodiments are set forth in the forearm 20A as shown. A PCB 220 iselectrically coupled to lead A of a cautery power line (such as cauteryline 104 discussed above) that is coupled to an external power source,such as a cautery generator. The PCB 220 is further electrically coupledto a pin 222, which is electrically coupled to socket 224 (defined in orcoupled—electrically and mechanically—to a proximal end of the leadscrew 210 discussed above) and is slidably positioned within the socket224. The lead screw 210 is coupled electrically and mechanically to theend effector pin 214 as best shown in FIG. 5C. As such, energizing leadA in the cautery line 104 energizes channel A in the bipolar cautery endeffector 28A. Certain embodiments of the forearm further comprise atleast one insulator 225.

As shown in FIGS. 6B and 7 , the channel B components are set forth inthe forearm 20A as shown. The PCB 220 discussed above is alsoelectrically coupled to lead B of a cautery power line (such as cauteryline 104 discussed above) that is coupled to an external power source.The PCB 220 is further electrically coupled to a conducting rod 240,which is electrically coupled to a wiper 242. The wiper 242 is atensioned component that supported on one end by a mechanical strut 244.An insulating insert 246 is positioned between the wiper 242 and themechanical strut 244. At its free end, the wiper 242 is supported by apreloader 248. Based on this configuration, the wiper 242 is loaded orurged—like a leaf spring—against the tool base interface 190 (discussedabove) and thus becomes electrically coupled to the tool base interface190. The tool base interface 190 is mechanically coupled to the endeffector 28A and electrically coupled to channel B of that end effector28A. As such, energizing lead B in the cautery line 104 energizeschannel B in the bipolar cautery end effector 28A. In exemplaryembodiments, the channel A components are electrically isolated from thechannel B components, and both channels are electrically isolated fromthe chassis to enhance patient safety.

In one implementation, the forearm 20A has at least one fluidic sealinterface that helps to prevent fluid ingress into the forearm 20A. Onesuch mechanism is a monolithic single-piece housing 260 as depicted inFIGS. 9A and 9B according to one embodiment. The one-piece nature of thehousing 260 greatly reduces the number of interfaces that must be sealedand thus reduces the number of interfaces where fluidic leaks are morelikely to occur. The housing 260 is configured to slide over theinternal components of the forearm 20A. That is, the proximal end of thehousing 260 defines an opening that can be positioned over the forearm20A (or the forearm 20A is inserted into the lumen) until the housing260 is correctly positioned over the forearm 20A. As best shown in FIG.9B, the housing 260 can have an O-ring 262 positioned in a groovedefined in the housing 260 around the hole 264 defined in the distal endof the housing 260. The hole 264 is configured to receive the endeffector 28A, which in certain embodiments is the distal end of the rollhub 186. In one embodiment, the roll hub 186 (discussed above) ispositioned through the hole 264 such that the O-ring 262 is configuredto be preloaded against that roll hub 186, thereby forming a fluidicseal between the housing 260 and the external surface of the hub 186,which in certain embodiments may further comprise a stainless steel ringto enhance the seal.

In a further embodiment as shown in FIG. 8A, the forearm 20A has twogrooves 270, 272 defined in the external portion of the forearm housing260 (as described above). The grooves 270, 272 can be configured toprovide an attachment point for an outer barrier (such as the firstbarrier 300 described in further detail below) such that an elastic banddefined in the opening of the sleeve of the inner barrier 300 can bepositioned in the grooves 270, 272, thereby enhancing the coupling ofthe barrier 300 to the housing 260 and thus enhancing the fluidic seal.In one embodiment, the grooves 270, 272 encircle the entire forearmhousing 260. Alternatively, the first barrier 300 can be bonded to thehousing 260 via an adhesive or welding. In a further alternative, thehousing 260 and the first barrier 300 can be fabricated as a singlepiece.

According to another implementation as shown in FIG. 8A, the forearm 20Ahousing 260 can have a groove 280 defined in the housing 260 around thehole 282 in the housing 260 through which the end effector 28A ispositioned. The groove 280 can be configured to provide an attachmentpoint for an outer barrier (such as the outer barrier 310 described infurther detail below) such that an elastic band defined in the openingof the sleeve of the second barrier 310 can be positioned in the grooves270, 272, thereby enhancing the coupling of the second barrier 310 tothe housing 260 and thus enhancing the fluidic seal.

As shown in FIG. 8B, another fluidic seal can be provided according toanother embodiment in the form of a flexible membrane 290 that isattached at one end to the lead screw 210 (discussed above) and at theother end to the tool base interface 190 (discussed above). Morespecifically, the membrane 290 is coupled to the lead screw 210 at theO-ring 292 and is coupled to the tool base interface 190 at the groove292. In one embodiment, the membrane 290 is retained at the groove 292with an attachment mechanism such as a cinch (not shown). This membrane290 serves to provide a fluidic seal for the internal components of theforearm 20A against any external fluids. In one implementation, the sealis maintained whether the end effector 28A is coupled to the forearm 20Aor not. Alternatively, the membrane 290 can be replaced with a metallicbellows.

Additional fluidic seals can be provided according to certainembodiments as depicted in FIGS. 10A and 10B. As shown in FIGS. 10A and10B, the device 10 can have two fluidically sealed barriers protectingeach of the device arms 14A, 14B. The first barrier (also referred toherein as an “inner barrier”) 300 is shown in FIG. 10A, in which it ispositioned around each arm and coupled at the sleeve ends 302A, 302B tothe device body 12 via elastic components 304A, 304B that urge theopenings in the sleeve ends 302A, 302B, thereby enhancing the fluidicseal. In the embodiment as shown, the elastic components 304A, 304B arepositioned around the forearms of the arms 14A at the distal ends of theforearms. Alternatively as described in detail above with respect toFIG. 8A, the elastic components 304A, 304B can be positioned in groovesdefined in the forearms (such as grooves 270, 272 described above).

In one embodiment, the inner barrier 300 is a membrane that ispermanently bonded to the device 10 and is not removed for the entireoperational life of the device 10. The barrier 300 is sterilized withthe device 10.

The second barrier (also referred to herein as an “outer barrier”) 310is shown in FIG. 10B, in which is positioned around each arm 14A, 14B,over the inner barrier 300 discussed above, and coupled at the sleeveends 312A, 312B to the device body 12 via elastic components 314A, 314Bthat urge the openings at the sleeve ends 312A, 312B against the arms14A, 14B, thereby enhancing the fluid seal.

FIGS. 11A and 11B depict one embodiment of a rigid-flex PCB component320 that can be used as the PCB component within the device embodimentsdescribed above. It is understood that the rigid-flex assembly is aknown fabrication method. In one embodiment, the PCB component 320 thathas been assembled using a known fabrication method, but is customdesigned and fabricated.

In use as shown in FIGS. 12A-17D, the device embodiments disclosed andcontemplated herein are configured to have a consistent cross-sectionand minimal profile, thereby enhancing the ease of inserting the devicethrough an incision and into a patient's cavity. Further, in oneembodiment, the device 10 can be inserted via a specific set of stepsthat maintain the minimal profile and consistent cross-section in anoptimal fashion. As shown in FIG. 12 , the device 10 is being preparedto be inserted through the incision 330 and into the cavity 340. Notethat the arms 14A, 14B of the device 10 are straight. In FIG. 13 , thedevice 10 is inserted such that the forearms 20A, 20B are positioned inthe cavity 340. As shown in FIG. 14 , the forearms 20A, 20B can then berotated as shown to maximize the amount of the device 10 that can beinserted. As the insertion continues as shown in FIG. 15 , the upperarms 18A, 18B are also rotated to optimize the surgical space. At thispoint, the arms 14A, 14B can be moved into their operational position,first by urging them to move in opposite directions as shown in FIG. 16.

Finally, the arms 14A, 14B are rotated so that the elbows are projectingoutward in FIG. 17 , thereby moving the arms 14A, 14B into theirpreferred operational position. In exemplary embodiments, the device maybe rotated and/or tilted inside the patient relative to the initialinsert position, so as to provide the user with access to all fourquadrants from the single insertion. Further, as is apparent from theinsertion of the device depicted in FIGS. 12A-17D, the arms of thedevice are inserted in parallel, rather than sequentially, as had beenthe case in prior surgical robotic devices.

In one implementation, the device 10 has at least one camera that isused in conjunction with the device 10. For example, a camera (notshown) such as a camera having two degrees of freedom (a pan-and-tiltcamera) having digital zoom could be used. In one embodiment, it isinserted through the camera lumen 32 defined in the proximal end of thedevice body 12 as best shown in FIG. 1C. According to oneimplementation, the camera can be controlled by the user or surgeonusing a foot controller and would be easy to remove, clean, andre-insert during a procedure. In another embodiment, the camera can be astandard laparoscope inserted through the same incision, through thelumen 32, or through a different incision.

While multiple embodiments are disclosed, still other embodiments of thepresent invention will become apparent to those skilled in the art fromthe following detailed description, which shows and describesillustrative embodiments of the invention. As will be realized, theinvention is capable of modifications in various obvious aspects, allwithout departing from the spirit and scope of the present invention.Accordingly, the drawings and detailed description are to be regarded asillustrative in nature and not restrictive.

Although the present invention has been described with reference topreferred embodiments, persons skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

What is claimed is:
 1. A surgical robotic system for performing surgeryon a patient, comprising: a. a robotic device sized to be positionedinto a cavity of the patient by way of a port positioned in an incisionof a patient, the device comprising: i. a unitary elongate device body;ii. a first shoulder joint movably coupled to a distal end of the devicebody; iii. a second shoulder joint movably coupled to the distal end ofthe device body; iv. a first movable segmented robotic arm operablycoupled to the first shoulder joint and comprising: A. a first upper armsegment; B. a first lower arm segment; C. a plurality of first armactuators and a plurality of first arm gears constructed and arranged totranslate movement of the first arm actuators to movement of the firstmovable segmented robotic arm; and D. a first operational component; andv. a second movable segmented robotic arm operably coupled to the secondshoulder joint and comprising: A. a second upper arm segment; B. asecond lower arm segment; and C. a plurality of second arm actuators andsecond arm gears constructed and arranged to translate movement of thesecond arm actuators to movement of the second movable segmented roboticarm; and D. a second operational component; and b. a console inelectrical communication with the robotic device, the console configuredto control the robotic device from outside the patient, wherein: a. theunitary device body is configured to be inserted into the port such thatthe distal end is within the cavity and at least a portion of the devicebody is external to the cavity, and b. the first and second moveablesegmented arms are capable of being positioned substantially parallelwith a longitudinal axis of the device body for insertion by way of theport.
 2. The surgical robotic system of claim 1, wherein: a. the firstupper arm segment comprises a housing enclosing a portion of theplurality of first arm actuators; b. the first lower arm segmentcomprises a housing enclosing at least one of the plurality of first armactuators; c. the second upper arm segment comprises a housing enclosinga portion of the plurality of second arm actuators; and d. the secondlower arm segment comprises a housing enclosing at least one of theplurality of second arm actuators.
 3. The surgical robotic system ofclaim 1, wherein at least one of the plurality of first arm actuatorsand the plurality of second arm actuators is a brushless DC motor. 4.The surgical robotic system of claim 1, wherein the device body furthercomprises a rigid-flex PCB in operational communication with at leastone of the plurality of first arm actuators and the plurality of secondarm actuators and is configured to perform yaw and pitch functions. 5.The surgical robotic system of claim 1, wherein the first movablesegmented robotic arm further comprises a first elbow joint, wherein thefirst upper arm segment is configured to be capable of roll, pitch andyaw relative to the first shoulder joint and the first lower arm isconfigured to be capable of yaw relative to the first upper arm by wayof the elbow joint.
 6. The surgical robotic system of claim 5, whereinthe first operational component is chosen from a group consisting of agrasping component, a cauterizing component, a suturing component, animaging component, an irrigation component, a suction component, anoperational arm component, a sensor component, and a lighting component.7. The surgical robotic system of claim 5, wherein the secondoperational component is chosen from a group consisting of a graspingcomponent, a cauterizing component, a suturing component, an imagingcomponent, an irrigation component, a suction component, an operationalarm component, a sensor component, and a lighting component.
 8. Asurgical robotic system for performing minimally-invasive surgery on apatient, comprising: a. a robotic device sized to be positioned into apatient body cavity, the device comprising: i. a unitary elongate devicebody constructed and sized to be positioned through an incision and intothe body cavity of the patient; ii. a first shoulder joint movablycoupled to a distal end of the unitary elongate device body; iii. asecond shoulder joint movably coupled to the distal end of the unitaryelongate device body; iv. a first movable segmented robotic arm operablycoupled to the first shoulder joint and comprising: A. a first upper armsegment comprising a housing enclosing a plurality of first upper armactuators; B. a first lower arm segment comprising a housing enclosingat least one first lower arm actuator; C. a plurality of first arm gearsconstructed and arranged to translate movement of the first armactuators to movement of the first movable segmented robotic arm; and D.a first operational component; and v. a second movable segmented roboticarm operably coupled to the second shoulder joint and comprising: A. asecond upper arm segment comprising a housing enclosing a plurality ofsecond upper arm actuators; B. a second lower arm segment comprising ahousing enclosing at least one second lower arm actuator; and C. aplurality of second arm gears constructed and arranged to translatemovement of the second arm actuators to movement of the second movablesegmented robotic arm; and D. a second operational component; and b. aconsole for control of the robotic device from outside the patient byway of a port positioned in the incision, the console in electricalcommunication with the robotic device.
 9. The surgical robotic system ofclaim 8, wherein: a. the first lower robotic arm segment comprises afirst elbow joint, b. the second lower robotic arm segment comprises asecond elbow joint, c. the first lower arm and second lower arm areconfigured to be capable of yaw relative to the upper arm by way of thefirst and second elbow joints, and d. the first and second moveablesegmented arms are capable of being positioned substantially parallelwith a longitudinal axis of the device body for insertion by way of theport.
 10. The surgical robotic system of claim 9, wherein the firstoperational component is chosen from a group consisting of a graspingcomponent, a cauterizing component, a suturing component, an imagingcomponent, an irrigation component, a suction component, an operationalarm component, a sensor component, and a lighting component.
 11. Thesurgical robotic system of claim 9, wherein the second operationalcomponent is chosen from a group consisting of a grasping component, acauterizing component, a suturing component, an imaging component, anirrigation component, a suction component, an operational arm component,a sensor component, and a lighting component.
 12. A minimally invasivesurgery system, comprising: a. a robotic device comprising: i. a unitaryelongate device body having proximal and distal ends and beingconstructed and sized to be positioned through an incision and into thebody cavity of the patient; ii. a first movable segmented robotic armoperably coupled to the distal end of the unitary elongate device bodyand comprising: A. a first shoulder joint movably coupled to the distalend of the device body; B. a first upper arm segment; C. a first elbowjoint; D. a first lower arm segment; E. a plurality of first armactuators and a plurality of first arm gears constructed and arranged totranslate movement of the first arm actuators to movement of the firstmovable segmented robotic arm; and F. a first operational component; andiii. a second movable segmented robotic arm operably coupled to thedistal end of the unitary elongate device body and comprising: A. asecond shoulder joint movably coupled to the distal end of the devicebody; B. a second upper arm segment; C. a second elbow joint; D. asecond lower arm segment; and E. a plurality of second arm actuators anda plurality of second arm gears constructed and arranged to translatemovement of the second arm actuators to movement of the second movablesegmented robotic arm; and F. a second operational component; whereinthe robotic device is constructed and arranged for insertion andoperation via: a. positioning the first and second moveable segmentedarms substantially in line with a longitudinal axis of the device bodyprior to insertion into a body cavity of a patient, b. inserting thedistal end of the robotic device into the body cavity of the patientthrough a port in communication with the body cavity such that the firstand second movable segmented robotic arms are disposed entirely withinthe body cavity and the unitary elongate device body is disposed in theport such that the distal end of the device body is disposed within thebody cavity and the proximal end of the device body is disposed outsidethe body cavity, and c. rotating the first and second moveable segmentedarms such that the first and second elbow joints project outward fromthe longitudinal axis.
 13. The system of claim 12, wherein the roboticdevice is constructed and arranged to be rotated and/or tilted insidethe patient relative to the initial insert position.
 14. The system ofclaim 12, wherein the first and second moveable segmented arms areconstructed and arranged for performing yaw and pitch functions.
 15. Thesystem of claim 12, wherein the device body further comprises a firstrigid-flex PCB in operational communication with the first movablesegmented robotic arm and a second rigid-flex PCB in operationalcommunication with the second movable segmented robotic arm.
 16. Thesurgical robotic system of claim 12, wherein the first and second upperarm segments are constructed and arranged to be capable of roll, pitchand yaw relative to the first and second shoulder joints, respectively,and the first and second lower arm segments are configured to be capableof yaw relative to the first and second upper arm segments by way of thefirst and second elbow joints, respectively.
 17. The surgical roboticsystem of claim 12, further comprising at least one absolute positionsensor comprising a magnetic encoder.
 18. The surgical robotic system ofclaim 12, wherein: a. the first upper arm segment comprises a housingenclosing a portion of the plurality of first arm actuators; b. thefirst lower arm segment comprises a housing enclosing at least one ofthe plurality of first arm actuators; c. the second upper arm segmentcomprises a housing enclosing a portion of the plurality of second armactuators; and d. the second lower arm segment comprises a housingenclosing at least one of the plurality of second arm actuators.